Shingled solar cell module

Abstract

A high efficiency configuration for a solar cell module comprises solar cells arranged in a shingled manner to form super cells, which may be arranged to efficiently use the area of the solar module, reduce series resistance, and increase module efficiency.

What is claimed is: 
     
         1 . An apparatus comprising:
 a first super cell disposed on a solar module front surface and comprising a plurality of solar cells, each having a breakdown voltage of greater than about 10V;   a first ribbon conductor electrically connected with a rear surface contact of the first super cell to provide a first hidden tap to an electrical component;   a second super cell disposed on the solar module front surface and comprising a plurality of solar cells, each having a breakdown voltage of greater than about 10V; and   a second ribbon conductor electrically connected with a rear surface contact of the second super cell to provide a second hidden tap.   
     
     
         2 . An apparatus as in  claim 1  wherein the electrical component comprises a bypass diode. 
     
     
         3 . An apparatus as in  claim 2  wherein the bypass diode is located on a solar module rear surface. 
     
     
         4 . An apparatus as in  claim 3  wherein the bypass diode is located outside of a junction box. 
     
     
         5 . An apparatus as in  claim 4  wherein the junction box comprises a single terminal. 
     
     
         6 . An apparatus as in  claim 3  wherein the bypass diode is positioned near a solar module edge. 
     
     
         7 . An apparatus as in  claim 2  wherein the bypass diode is positioned in a laminate structure. 
     
     
         8 . An apparatus as in  claim 7  wherein the first super cell is encapsulated within the laminate structure. 
     
     
         9 . An apparatus as in  claim 8  wherein the bypass diode is positioned around a solar module perimeter. 
     
     
         10 . An apparatus as in  claim 1  wherein the first super cell is connected in series with the second super cell. 
     
     
         11 . An apparatus as in  claim 10  wherein:
 the first super cell and the second super cell form a first pair; and 
 the apparatus further comprises two additional super cells in a second pair connected in parallel with the first pair. 
 
     
     
         12 . An apparatus as in  claim 10  wherein the second hidden tap is connected to the electrical component. 
     
     
         13 . An apparatus as in  claim 12  wherein the electrical component comprises a bypass diode. 
     
     
         14 . An apparatus as in  claim 13  wherein the first super cell comprises not fewer than  19  solar cells. 
     
     
         15 . An apparatus as in  claim 12  wherein the electrical component comprises a power management system. 
     
     
         16 . An apparatus as in  claim 1  wherein the electrical component comprises a switch. 
     
     
         17 . An apparatus as in  claim 16  further comprising a voltage sensing controller in communication with the switch. 
     
     
         18 . An apparatus as in  claim 16  wherein the switch is in communication with a central inverter. 
     
     
         19 . An apparatus as in  claim 1  wherein the electrical component comprises a power management device configured to,
 receive a voltage output of the first super cell; 
 based upon the voltage, determine if a solar cell of the first super cell is in reverse bias; and 
 disconnect the solar cell in reverse bias from a super cell module circuit. 
 
     
     
         20 . An apparatus as in  claim 1  wherein the electrical component comprises an inverter. 
     
     
         21 . An apparatus as in  claim 20  wherein the inverter comprises a DC/AC micro-inverter. 
     
     
         22 . An apparatus as in  claim 1  wherein the electrical component comprises a solar module terminal. 
     
     
         23 . An apparatus as in  claim 22  wherein the solar module terminal is a single solar module terminal within a junction box. 
     
     
         24 . An apparatus as in  claim 1  wherein the electrical component is located on a solar module rear surface. 
     
     
         25 . An apparatus as in  claim 1  wherein the rear surface contact is located away from an end of the first super cell overlapping the second super cell. 
     
     
         26 . An apparatus as in  claim 1  wherein the first super cell has a length in a direction of current flow of at least about 500 mm. 
     
     
         27 . An apparatus as in  claim 1  wherein a solar cell of the first super cell comprises a feature configured to confine spreading of the adhesive. 
     
     
         28 . An apparatus as in  claim 27  wherein the feature comprises a raised feature. 
     
     
         29 . An apparatus as in  claim 28  wherein the feature comprises metallization. 
     
     
         30 . An apparatus as in  claim 27  wherein the feature comprises a recessed feature. 
     
     
         31 . An apparatus as in  claim 27  wherein the feature is on a back side of the solar cell. 
     
     
         32 . An apparatus as in  claim 27  wherein the feature is hidden by an adjacent solar cell of the first super cell. 
     
     
         33 . An apparatus as in  claim 1  wherein a solar cell of the first super cell comprises a chamfered portion. 
     
     
         34 . An apparatus as in  claim 33  wherein the first super cell further comprises another solar cell having a chamfered portion, and wherein a long side of the solar cell is in electrical contact with a long side of the other solar cell that has a similar length. 
     
     
         35 . An apparatus as in  claim 33  wherein the first super cell further comprises another solar cell lacking chamfered corners, and the solar cell and the other solar cell have a same area exposed to light. 
     
     
         36 . An apparatus as in  claim 1  wherein:
 the first super cell is arranged with the second super cell in parallel rows on a backing sheet front surface; and 
 the backing sheet is white and comprises darkened stripes of location and width corresponding to gaps between the first super cell and the second super cell. 
 
     
     
         37 . An apparatus as in  claim 1  wherein the first super cell is disposed on a first backing to form a module having a top conductive ribbon on the module front surface facing a direction of solar energy, the apparatus further comprising:
 a third super cell disposed on a second backing to form a different module having a bottom ribbon on a second side facing a direction away from the direction of the solar energy, 
 wherein the different module overlaps and is bonded to a portion of the module including the top ribbon. 
 
     
     
         38 . An apparatus as in  claim 37  wherein the different module is bonded to the module by adhesive. 
     
     
         39 . An apparatus as in  claim 37  further comprising a junction box overlapped by the different module. 
     
     
         40 . An apparatus as in  claim 39  wherein the different module is bonded to the module by a mating arrangement between the junction box and another junction box on the different module.